PROJECT SPOTLIGHT
TOGETHER TO A SUCCESSFUL HVAC CONNECTOR
“Ekko-Meister is the ideal partner for challenging development projects – and not just during series production.”
Time pressure and looking for a solution
For our HVAC* project, we needed a connector to serve as the interface between the sensor and the process monitoring system. With the HVAC market growing so quickly, we had a tight schedule to meet. This meant we had to quickly find a near-series prototype tool and effective development support.
Ekko-Meister enjoys tackling challenges and offers a high degree of automation. Throughout the development process, they consistently provided us with expert support. We truly valued their solution-oriented and collaborative approach. Ultimately, their competitive offer made them our top choice as a development and series partner.
How could Ekko-Meister convince you?
From idea to reality
Together, we reviewed the existing concept and, unfortunately, had to discard it based on the findings. While working on our new component design, we built valuable expertise in overmolded connector pins together.
Thanks to Ekko-Meister’s custom-built separation and assembly machines, we’re enjoying cost-effective components made in Switzerland that meet our cost-saving goals.
*Building Engineering: Heating, ventilation, and air conditioning. Our customer is a leading international manufacturer of components for the precise measurement of pressure and flow.
The project from Ekko-Meister’s perspective
Our customer initially only requested the production of the contact pins (stamped and bent part). But since we have a modern in-house plastic injection molding department and could offer the entire assembly, including development, they entrusted us to manufacture the complete connector.
From the start, we worked closely with the customer to successfully bring this new type of connector to market maturity.
Design optimization thanks to prototype development
The first prototypes showed that the original concept was unsuitable, so we completely revised the design together. The new connector was then designed in two versions: as a plug-in or screw-in variant.
To meet the tight project timeline, we created a single-track pre-series tool, which helped us stay on schedule while simultaneously preparing the multi-track series production tool. By using our simultaneous engineering** approach, we efficiently coordinated and optimized every step of the process—from development to design and production.
In-house automation for efficient production
The production involved several steps, including stamping on the strip, testing, galvanizing, bending/separating, feeding into the injection molding machine, overmolding with high-performance plastic, and final quality inspection. Our custom-developed manufacturing system for this project saved a lot of time and costs.
From engineering to the finished part, we handle everything in-house except for electroplating. This way, we ensure everything runs smoothly, even for challenging projects with tight deadlines.
We’d like to thank our long-time customer for their trust and great teamwork. This project shows how innovative ideas come to life through shared investment and mutual support.
** With simultaneous engineering, design, prototyping, and production preparation go hand in hand, allowing us to react immediately to feedback. For our customers, this means faster development times, better product quality from instant improvements, and seamless coordination of all processes.
